Eave lining system

ABSTRACT

An eave lining system for buildings including an eave lining sheet pre-finished on at least one exposed surface and securing means for affixing the eave sheet to a support surface is provided. The eave sheet and securing means are configured such that minimal post installation finishing is required. In a preferred form, the system includes a pre-finished corner trim system for concealing and finishing the joint between the eave lining sheet and the adjacent building surface. The trim system can be a two-part system including an inner core element that is secured to the eave support structure or adjacent building surface, and an outer pre-finished clip on cover element. The cover element can be made of standard straight length sections and custom pre-formed corner pieces that sit over the ends of the straight sections.

RELATED APPLICATIONS

This application claims priority to Australian Provisional ApplicationNo. 2003906615, filed Nov. 28, 2003, and Australian ProvisionalApplication No. 2004903302, filed Jun. 17, 2004, and AustralianProvisional Application No. 2004903567, filed Jun. 29, 2004, theentirety of each of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to building construction, andmore particularly to eave lining systems for building structures andinstallation of the same.

2. Description of the Related Art

In the construction industry, the installation of eave linings istypically a multi-stage process. Eave sheet used to line the eaves isgenerally produced in set lengths and widths. The sheet must betransported to site, nailed into position on the building. The jointsections are typically set, concealed or connected using joining strips.A finish is then applied to the entire assembly after installation. Insome cases, a paint or coating is applied to the assembly, and sometimesthe eave sheets must be painted more than once with an undercoat and atopcoat.

These finishing processes after installation add greatly to the expenseof installing eave linings. The labor, paint and setting costs as wellas additional time taken to paint and/or set the eaves all add to theinstallation cost. Moreover, eaves are most often situated high up onbuilding structures and therefore, the installation would incuradditional costs for scaffolding equipment to elevate the tradesmenduring the eave finishing and painting process. This is a particularproblem in the construction of many project, kit and pre-finishedbuildings where the only parts of the entire building requiring paintingare the eaves. Accordingly, painters must be brought in specifically andonly for that task. As such the efficiency is reduced.

Another problem is the consistency of the painting when done onsite. Itis often the case that the coverage applied by hand painting eaves isnot uniformly thick. This may result in patchy protection and/orappearance. Similar problems also apply in relation to the setting andconcealing of various joints where this is required.

It is an object of the present invention to overcome or ameliorate oneor more of these disadvantages of prior art, or at least to provide auseful alternative.

SUMMARY OF THE INVENTION

In one aspect, the preferred embodiments of the present inventionprovide an eave lining sheet which is pre-finished on at least oneexposed surface prior to installation on building structure. The atleast one pre-finished surface comprises a layer selected from the groupconsisting of paint, coating, and laminate. In one embodiment, the sheetis pre-finished by the use of pigmented base materials and/or additivessuch that minimal further finishing is required. In another embodiment,the eave lining sheet comprises a release liner positioned adjacent tothe exposed surface so as to protect the pre-finished surface fromdamage.

In another aspect, the preferred embodiments of the present inventionprovide an eave lining system for buildings. The system includes an eavelining sheet having at least one exposed surface that is pre-finished,and a securing member for affixing the eave lining sheet to a supportsurface. The eave sheet and the securing member are preferablyconfigured such that minimal post installation finish is required. Inone embodiment, the system further includes a joining strip for joininga peripheral edge of the eave sheet with a peripheral edge of a likeeave sheet. The joining strip is preferably colored such that minimalpost installation finishing is required.

In another embodiment, the system further includes a pre-finished cornertrim system for concealing and finishing a joint area between the eavelining sheet and an adjacent building surface. Preferably, the trimsystem is a two-part system comprising an inner core element that isadapted to be secured to the support surface or the adjacent buildingsurface, and an outer pre-finished clip-on cover element. In oneembodiment, the cover element comprises standard straight lengthsections and custom pre-formed corner pieces. The corner pieces arepreferably positioned over at least a portion of the straight lengthsection to allow for expansion and reduce the need for accurate lengthcuts on the sections. The inner core trim element can be solid or hollowand has a shape selected from the group consisting of rectangular, quad,and fillet profile, wherein rebates are formed adjacent diametricallyopposed corner edges for accepting in-turned lip portions oncorresponding outer trim cover portions having a similar general profileas the exposed portion of the inner core element. In one embodiment, therebates are preferably formed on all edges or multiple sets of corneredges of the trim element.

In certain embodiments, the inner core element has a thin walled profiledefining one or more surfaces for connection to the eaves sheet oradjacent building surface, wherein the core element also includes asecuring member to secure thereto a cover element of an externalprofile. In another embodiment, the inner core element has twosubstantially perpendicular arms wherein the ends of each arm areconfigured to accept and retain outer trim cover portions having thesame or a different general profile to the inner element. Preferably,the securing element is selected from the group consisting of screws,nails, staples, plugs, glues, tapes, and combinations thereof. In apreferred embodiment, at least a portion of the screws, nails and plugsare color coordinated with the eave lining sheet. In yet anotherembodiment, one or more components of the system include openings orperforations configured to provide a predetermined amount of ventilationto selected parts of the building. Preferably, the openings orperforations are provided in one or more of parts selected from thegroup consisting of eave lining sheets, sheet joining strips, and trimcomponents.

In yet another aspect, the preferred embodiments of the presentinvention provide a method of installing an eave lining on a buildingstructure. The method comprises providing an eave lining sheet having atleast one pre-finished surface and installing the eave lining sheet onthe building structure with the pre-finished surface exposed. In oneembodiment, the method further comprises securing the pre-finished eavelining sheet using at least one securing member selected from the groupconsisting of screws, nails, staples, plugs, glues, and tapes.

In yet another aspect, the preferred embodiments of the presentinvention provide a two-part trim system for concealing joint regions inbuilding structures. The trim system comprises a base securable over oradjacent a joint region to be concealed and a cover element connectableto the base to conceal the joint region.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial sectional side view of a building showing an eavesystem in accordance with a preferred embodiment of the invention;

FIG. 2 is sectional plan view of the system shown in FIG. 1;

FIG. 3A illustrates a nail in accordance with a preferred embodiment ofthe invention;

FIG. 3B illustrates a screw in accordance with a preferred embodiment ofthe invention;

FIG. 3C illustrates a quick fix fastener plug in accordance with apreferred embodiment of the invention;

FIG. 4 is a view showing a protective hammer pad in accordance with apreferred embodiment of the invention;

FIG. 5 is a view showing a hammer protector cap in accordance with apreferred embodiment of the invention;

FIG. 6 is a sectional view of an abutment join “on frame” between twoeave boards in accordance with a preferred embodiment of the invention;

FIG. 7 is a sectional view of an abutment join “off frame” between twoeave boards in accordance with a preferred embodiment of the invention;

FIG. 8 is a sectional side view of part of a building showing an eavelining system in accordance with a preferred embodiment of the inventionhaving an alternative two part trim system;

FIG. 9A shows one embodiment of a straight inner trim section of thesystem shown in FIG. 8;

FIG. 9B shows an alternative embodiment of a straight inner trim sectionof the system shown in FIG. 8;

FIG. 10 shows an embodiment of a straight outer trim section for usewith the inner trim section of FIG. 9;

FIG. 11 shows an embodiment of a partly assembled system using the innerand outer trim sections of FIGS. 9 and 10 along with a custom outerexternal corner piece;

FIG. 12 shows a variety of alternative profiles for the two part trimsystem of FIGS. 8 to 11;

FIG. 13 shows a eave lining system in accordance with a preferredembodiment of the invention that incorporates a vented eave panel and/oreave panel trim arrangement.

FIG. 14 is a detailed view of the vented eave panel trim arrangementshown in FIG. 13; and

FIG. 15 shows one embodiment of a ventilated eave panel end join stripparticularly suited for, but not limited to use with the system of FIG.13.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiments of the invention will be describedpredominantly in the context of installation of eave linings. It will beappreciated, however, that the invention is not limited to thisparticular field of use, being also applicable to other areas ofbuilding and construction.

In general terms, certain preferred embodiments of the present inventionprovide a pre-finished eave system for buildings such that no additionalpainting or finishing of the eaves is required after installation. Thepre-finished eave system generally includes a pre-finished eave liningsheet and a securing member for attaching the sheet to a buildingstructure.

In one embodiment, the eave lining sheets are made of fiber reinforcedcement (FRC), for example those classified as Type A Category 3 inaccordance with AS/NZS 2908.2 ‘Cellulose-Cement Products’. However, inalternative embodiments, the sheets may be of other suitable materials.For example, it will be appreciated that sheets formed of wood, metal,plastics, or other suitable material may replace or be used inconjunction with the FRC sheets of this embodiment and are within thescope of the invention.

The sheets are preferably produced in a variety of standard lengths,widths and generally will be a standard thickness so that the sheetswill be flush on installation. Table 1 below lists certain preferredsheet sizes, however it will be appreciated that the product may beproduced in any size or thickness as required. TABLE 1 Product SizesLength Width Thickness (mm): (mm): (mm): 2400 450 4.5 2400 600 4.5 2400750 4.5 2400 1200 4.5

In some implementations, the eave lining sheets may also be perforatedthrough their thickness with a predetermined number and arrangement ofslots, holes, or other types of perforation. These perforations providea predetermined amount of airflow through the sheet, in turn providingventilation to the roof or wall cavity when the sheet is installed.

In one embodiment, the eave lining sheets are pre-finished on at leastone side with a protective paint or coating. Painting can be anautomated process conducted at a purpose built production facility andmay be applied using conventional techniques, such as spraying, rollcoating, curtain coating, or powder coating. The paint may be cured bythermal means or by radiation or a combination thereof. The paint may beapplied in one or more coats with or without an undercoat layer,depending on the type and color of paint or thickness of paint layerrequired.

The sheets may also be pre-finished using durable laminates such asFormica® high pressure laminates or durable polymeric films such asTedlar® fluoropolymer films. Such laminates are preferably applied tothe surface of the sheet with a suitable adhesive, such as apolyurethane adhesive. The sheets may also be colored using organic orinorganic pigments incorporated directly into the fibercement. Thesheets may also be coated with treatments to prevent the accumulation ofmildew and fungus which may form during storage and when installed.Other possible coatings maybe applied to help fire retardation, repelinsects or provide insulation characteristics. These coatings may beapplied under or on top of the paint layer or may be additives to thepaint itself.

While it is preferred that the sheets be painted in a factory and in aform which is substantially or completely pre-finished, it will beappreciated that the invention may be applied to sheets that are raw orunpainted and unfinished at purchase.

To reduce damage to the eaves during storage and shipment, thepre-finished eave sheet may be prepared by covering the surfaces of thesheet with a one or more removable protective coatings or laminates.This process is described in detail by the Applicant's corresponding,co-pending U.S. application Ser. No. 10/620,711 filed Jul. 16, 2003,which is hereby incorporated by reference in its entirety.Alternatively, the removable protective coating may be spray-applied orapplied as a transfer film from a backing material. Preferably, thelaminate forms a barrier substantially preventing the surface of theeaves from being damaged, marked or scratched. Once at the buildingsite, the protective layer can be stripped off either before, after orduring installation. In one embodiment, the removable protective layeris preferably stripped after installation is complete, in order toprotect the pre-finished panel surfaces from fingerprints, scratches andthe like.

Referring to the drawings, FIG. 1 illustrates a eave lining sheet 1 ofone preferred embodiment installed on a building structure. As shown inFIG. 1, the sheet 1 is attached to a eave support structure 4. As shownin FIGS. 1 and 2, the support structure 4 is generally a frame work ofeave battens made of steel or timber. In alternative embodiments, theeave lining sheet 1 may be attached to a substrate rather than the morecommon framework.

As can be seen in the embodiment shown in FIG. 1, the outer edge of theeave lining sheet fits into a groove 5 in an eave fascia board 6.Additionally, a pre-finished trim 7 is used at the inner edge to fillthe corner between the board 6 and the exterior wall.

The trim 7 can be a conventional wooden beading element, or instead canbe an extruded plastic strip or similar, with or without pre-madestraight section and/or corner connectors, the latter obviating the needto produce mitre cuts on site. Alternatively, a preferred two part trimsystem can be used as discussed below in reference to FIGS. 8 to 11. Incertain embodiments, the trim may also be made of a fibercementmaterial.

In other embodiments such as where grooves are not usually provided inthe fascia board, the eave lining sheet is nailed to a support and thefascia is installed afterwards. Any gap in the eave lining sheet and thefascia is then caulked or covered by a trim piece which can be of thekinds discussed above.

The eave lining sheet is preferably affixed to the supporting structureby a variety of methods. Such methods may include nails 8, screws 9,plugs 10, staples, glues or adhesive tapes alone or in combination.However, it is preferable that the fixing method and procedure does notdamage the eave board surface so that the need for any painting or touchup painting after installation is eliminated or kept to a minimum.

In certain preferred embodiments, screws and nails are fitted withcolored or painted heads to match the eave board finish. Accordingly, asshown in FIG. 4 special hammer pads 11 are provided so that the heads ofthe nails are not marked and the sheet not damaged. In an alternativeembodiment shown in FIG. 5, a soft plastic or rubber hammer protectivecap 11 a is provided along with a sleeve 11 b that allows the protectivecap to be fitted to hammers having a smaller head size. Another methodis to use colored caps in conjunction with screws and nails to cover theexposed head. Touch up may be required if non-prefinished fixers areused such as when stainless steel nails are specified in certain coastalareas.

As seen in FIGS. 6, 7, and 15, a joining strip 12 is provided tofacilitate joining of abutting boards. The joining strip 12 may beextruded plastic or another suitable material such as timber, rubber ora molded material. Preferably, the strip is color coordinated with theboards and do not require painting. The strips maybe used for jointsbetween sheets either on frame as shown in FIG. 6 or off frame as shownin FIG. 7. Alternatively, a strip may be pre-attached to one sheet witha suitable adhesive. While the strips of certain preferred embodimentsare of a generally “H” shaped profile, typically one internal leg isextended to facilitate attachment to the support structure as shown inFIG. 6. H-moulds may have an extended width and contain perforations toprovide venting as per the example shown in FIG. 15.

Referring next to FIGS. 8 to 11, there is shown an alternative andpreferred two part trim system for finishing and concealing the cornerbetween the eave sheets and the adjacent wall. This system uses an innertrim section which in the form illustrated in FIG. 9A shows a firstembodiment comprising a solid elongate core member 13A of generallyrectangular section, having rebates 14 adjacent to diametrically opposedcorner edges as shown. An alternative embodiment 13B is shown in FIG. 9Bwhich has rebate on all four edges so that the section can be installedin multiple orientations thereby simplifying the installation process.This modification can be applied to any profile that could be installedin more than one configuration. These inner trim cores can be made ofwood or a wood based composite like most of the conventional beadingsand trim sections used in the building industry. However, any other firmnailable material would be suitable including, for example, polymericexpanded foam materials or the like.

In other forms (not illustrated), the core element may be of a simplethin walled structure effectively defining a base plate which can besecured to the eave sheet and/or the adjacent building surface and whichincludes retaining means to which a clip on cover can be connected. Sucha base plate may be of a standard generally L shaped section and it iseach cover element only which is configured to the desired externalprofile.

The second part of the system comprises a pre-finished outer coverelement 15A that is adapted to sit over the inner core element 13. Inthe example provided, the outer core at a cover element has in-turnedlip formations 16 along its outer edges, such that the cover 15 can be“snapped on” to the core element and be retained thereby engagement ofthe lip formations 16 with the corresponding rebates 14. This coverelement can again be made of any material that would provide a requisiteresilience to effect a simple “snap-on” or “push-on” connection.Suitable materials may include various moulded or extruded polymers orpre-coated steel or aluminum sections.

Also, optionally forming part of the cover element portion of this trimsystem are pre-formed and pre-finished corner pieces such as 15 b shownin FIG. 11. The corner pieces can be made available in all commonconfigurations such as 90° (internal and external) and 135° external forbay windows and the like. Preferably, the custom corner sections areconfigured to sit over the straight section cover elements. Thissubstantially eliminates the need for accurate length cutting on thelong sections and allows for expansion and contraction which can be aproblem over long lengths.

The advantages of the two part inner and outer trim system aresignificant, in that the need for a skilled carpenter is eliminated anda simplified fixing process should be fairly quick to install. In thisregard, the inner core sections can be conveniently cut using, forexample, suitable plier type cutters and nailed into position withoutthe need to ensure a clean and accurate mitre join at the corner. Thestraight section cover elements can then be cut approximately to lengthin the same way and “snapped” onto the core elements. Finally, thecorner pieces can be clipped on top of the adjacent straight sectioncover portions and the finishing processes complete. There is no need tofinish or touch up joins, and no special skills are required as thereare no mitre joints to be cut and accurate length cutting at thestraight sections is not needed.

As can be seen from FIG. 12, the two part inner and outer trim systemcan be configured to any desired profile and is not limited to theexamples shown, nor is it limited to the use of solid core elements asshown in this illustration. Additional advantages are that the hiddenfixings of the two part trim section removes the need for touch up ofnails or screws. Furthermore the snap on trim sections allow for thermalexpansion of the building and the eaves components that is not possibleusing a 1 piece trim as is found in traditional eaves installationmethods. This ability to accommodate thermal expansion provides asignificant advantage over prior art systems. For example, for a fullyfixed trim that can't accommodate thermal expansion, buckling of thetrim can occur if the thermal expansion of the trim is greater than thewall resulting in an unsightly finish and possible nail pull out of thetrim. Alternatively, if the wall/substrate/etc expands more than a fullyfixed trim, the corner joints of the trim can open up and cause adeterioration in performance of the eaves system. These potentialproblems are avoided with the preferred system described above.

It will also be appreciated that while this two part trim system isparticularly suited to use in eave lining systems as described, it isequally applicable to other building applications where corner or indeedplanar joints need to be concealed in a simple manner that reduces theneed for highly skilled labor.

Turning finally to FIGS. 13, 14 and 15 there are shown furthervariations to the invention that incorporate venting means for enablingair and moisture vapor to flow from the wall and/or roof cavity toatmosphere. The arrangement shown in the accompanying figures isparticularly well suited to externally clad timber frame structures.However, the concept is not limited to this particular type of buildingstructure.

In order to provide ventilation to the wall cavity, a vented trim systemis optionally provided. While the illustrated form is based on thepreferred two part trim system, an equivalent single part trim componentcould also be used. The functional modification resides in the provisionof a trim wall extension strip 17 which has ventilation apertures 18provided therein.

In use, the vented eaves sheets are secured in the usual manner and anopening 19 is left between the external wall cladding and the sheetand/or eaves bearer. The modified trim element including the trim wallextension strip 17 is then secured to the eave sheet so that theextension strip bridges over the opening 19 as shown. If separate oradditional ventilation is required into the roof cavity, then a suitablyvented eaves sheet can also be used. Alternately, a roof space may beventilated by using a similar strip and re-orienting it so that thevented extension strip bridges a gap between the eaves sheet and theeaves support structure. The eaves sheets, whether ventilated orun-ventilated, can also be joined using a ventilated end join strip 12such as the kind shown in FIG. 15 which further enhances the ventilationand also provides an easy means of providing ventilation without usingperforated eave panels which may not be aesthetically acceptable.

It will be appreciated that all aspects of the invention providesignificant advantages over the prior art by minimizing or at leastsignificantly reducing the amount of time consuming and expensivein-situ post installation finishing required. This enables faster andmore economical installation of eaves, particularly where scaffoldingwould have normally been required. Furthermore, the trim arrangementincorporating overlapping corner and end finishing components overcomesproblems that can readily occur with fixed trim systems where there issome form of differential expansion between the trim and the adjacentsheets or elements of the building structure. Although the invention hasbeen described with reference to specific examples it will beappreciated by those skilled in the art that the invention may beembodied in many other forms.

1. An eave lining sheet which is pre-finished on at least one exposedsurface prior to installation on a building structure.
 2. An eave liningsheet according to claim 1, wherein the at least one pre-finishedsurface comprises a layer selected from the group consisting of paint,coating, and laminate.
 3. An eave lining sheet according to claim 1,wherein the sheet is pre-finished by use of pigmented base materialsand/or additives such that minimal further finishing is required.
 4. Aneave lining sheet according to claim 1, wherein the sheet furthercomprises a release liner positioned adjacent the exposed surface toprotect said pre-finished surface from handling damage.
 5. An eavelining system for buildings, including: an eave lining sheet having atleast one exposed surface that is pre-finished; and a securing memberfor affixing said eave sheet to a support surface.
 6. An eave liningsystem according to claim 5, wherein said eave sheet and securing memberare configured such that minimal post installation finish is required.7. An eave lining system according to claim 5, wherein the sheet is madefrom fiber reinforced cement.
 8. An eave lining system according toclaim 5 further including a joining strip for joining a peripheral edgeof said eave sheet with a peripheral edge of a like eave sheet.
 9. Aneave lining system according to claim 8, wherein said joining strip iscolored such that minimal post installation finishing is required. 10.An eave lining system according to claim 5 further including apre-finished corner trim system for concealing and finishing a jointarea between the eave lining sheet and an adjacent building surface. 11.An eave lining system according to claim 10, wherein the trim system isa two-part system comprising an inner core element that is secured tothe support surface or the adjacent building surface, and an outerpre-finished clip-on cover element.
 12. An eave lining system accordingto claim 10, wherein the cover element comprises standard straightlength sections and custom pre-formed corner pieces.
 13. An eave liningsystem according to claim 12, wherein the corner pieces are positionedover at least a portion of the straight length section to allow forexpansion and reduce the need for accurate length cuts on the sections.14. An eave lining system according to claim 11 wherein the inner coretrim element is solid or hollow and has a shape selected from the groupconsisting of rectangular, quad, and fillet profile, wherein rebates areformed adjacent diametrically opposed corner edges for acceptingin-turned lip portions on corresponding outer trim cover portions havinga similar general profile as the exposed portion of the inner coreelement.
 15. An eave lining system according to claim 14, whereinrebates are formed on all edges or multiple sets of corner edges of theinner core trim element.
 16. An eave lining system according to claim 11wherein the inner core element has a thin walled profile defining one ormore surfaces for connection to the eaves sheet or adjacent buildingsurface, wherein the element includes a securing member to securethereto a cover element of an external profile.
 17. An eave liningsystem according to claim 16, wherein the inner core element has twosubstantially perpendicular arms wherein the ends of each arm areconfigured to accept and retain outer trim cover portions having thesame or a different general profile to the inner element.
 18. An eavelining system according to claim 5 wherein the securing member isselected from the group consisting of screws, nails, staples, plugs,glues, tapes, and combinations thereof.
 19. An eave lining systemaccording to claim 18, wherein at least a portion of the screws, nailsand plugs are color coordinated with the eave sheet.
 20. An eave liningsystem according to claim 5 wherein one or more components of the systeminclude openings or perforations configured to provide a predeterminedamount of ventilation to selected parts of the building.
 21. An eavelining system according to claim 20, wherein the openings orperforations are provided in one or more of the eave sheets, sheetjoining strips or trim components.
 22. A method of installing an eavelining on a building structure, comprising: providing an eave liningsheet having at least one pre-finished surface; and installing the eavelining sheet on the building structure with the pre-finished surfaceexposed.
 23. A method of installing an eave lining according to claim 22further comprising securing the pre-finished eave lining sheet using atleast one securing member selected from the group consisting of screws,nails, staples, plugs, glues, and tapes.
 24. A two part trim system forconcealing joints in building structures, said trim system comprises: abase securable over or adjacent a joint to be concealed; and a coverelement connectable to said base to conceal said joint.